PSI - Issue 75

Mattias Clarin et al. / Procedia Structural Integrity 75 (2025) 467–473 Clarin et al. / Structural Integrity Procedia 00 (2025) 000 – 000

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Figure 1. Specimen geometry and dimensions in mm. 72 73 To ensure high repeatability and consistent geometry, welding was performed robotically using a rotary table 74 equipped with a custom-built jig (Fig. 2). The jig precisely positioned the studs relative to the specimen body, allowing 75 for uniform alignment and spacing across all specimens. 76 The specimens were manufactured using a fusion welding process. The welding method employed was Metal 77 Active Gas welding using a solid wire electrode and active shielding gas, in accordance with process number 135 of 78 ISO 4063. This method was selected for its arc stability, relatively high deposition rate, and ability to produce high- 79 quality, repeatable welds with consistent penetration. 80 Welding was carried out in the PB position using a Fronius CMT machine. A 1.0 mm diameter Esab Aristorod 69 81 solid wire electrode was used in combination with Mison 18 shielding gas (a mixture of argon with 18% CO₂), supplied 82 at a flow rate of 17 L/min. The torch was held at a 55° forehand angle, with no backing applied. Key process parameters 83 included a wire feed speed of 9 m/min, a travel speed of 46 cm/min, and a welding current of 208 A at 20.2 V. The 84 arc length was kept at 0%, and the torch was oriented transverse to the weld direction.

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87 Figure 2. Jig is used for positioning the circular flat stud (a), tack welded specimen (b), and circumferential weld with a 45° 88 offset angle for the start and stop position (c).

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